US4609519A - Processes for making molded composite panels - Google Patents

Processes for making molded composite panels Download PDF

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Publication number
US4609519A
US4609519A US06/590,481 US59048184A US4609519A US 4609519 A US4609519 A US 4609519A US 59048184 A US59048184 A US 59048184A US 4609519 A US4609519 A US 4609519A
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United States
Prior art keywords
mold
backing
blowing
air
assembly
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US06/590,481
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Inventor
Marcel Pichard
Pierre Brossy
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Saint Gobain Isover SA France
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Saint Gobain Isover SA France
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Assigned to ISOVER SAINT-GOBAIN LES MIROIRS" 18 AVENUE D`ALSACE, 92400 COURBEVOIE, FRANCE reassignment ISOVER SAINT-GOBAIN LES MIROIRS" 18 AVENUE D`ALSACE, 92400 COURBEVOIE, FRANCE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: BROSSY, PIERRE, PICHARD, MARCEL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • B29C33/04—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam
    • B29C33/046—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam using gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/12—Accessories for subsequent treating or working cast stock in situ
    • B22D11/128—Accessories for subsequent treating or working cast stock in situ for removing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C2043/3205—Particular pressure exerting means for making definite articles
    • B29C2043/3222—Particular pressure exerting means for making definite articles pressurized gas, e.g. air
    • B29C2043/3227—Particular pressure exerting means for making definite articles pressurized gas, e.g. air inside the material, e.g. gas injection compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2503/00—Use of resin-bonded materials as filler
    • B29K2503/04—Inorganic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0001—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties
    • B29K2995/0002—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/04—Treatment by energy or chemical effects using liquids, gas or steam
    • B32B2310/0445—Treatment by energy or chemical effects using liquids, gas or steam using gas or flames
    • B32B2310/0454—Hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/10—Natural fibres, e.g. wool, cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • Examples of composite panels of this type are stationary, removable, or movable baffles or screens that may be hung from the ceiling, formed into walls, etc., or made into hood-liners or interior fittings for the roofs of motor vehicles.
  • One of the problems encountered in the one-step molding of composite panels of the type described above stems from the difficulty of obtaining rapid, complete, and uniform polymerization in the thick, absorbent portion of low fiber-density as well as in the other parts (notably the thin edges) that are of high fiber-density.
  • the process comprises the following operations:
  • a stratified assembly comprising at least one piece of raw material, i.e., a layer of fibers containing a nonpolymerized binder, and at least one cover sheet is pressed between a mold and mold-backing;
  • hot air is blown into at least the thick section of the stratified assembly, entering from the side opposite the cover sheet;
  • the hot air flow is adjusted to supply the amount of heat needed for a uniform and quick polymerization of the binder
  • the thin, dense sections of the stratified assembly are simultaneously heated by contact.
  • the blowing operation is characterized by comprising at least two phases, the first blowing the hot air into the material to be molded from the side opposite the cover sheet, the second phase involving blowing in the reverse or opposite direction.
  • the phase of shaping the stratified assembly may be combined with the first blowing phase, particularly when the hot-air blowing operation under the invention is cross-over blowing, i.e., when the hot air enters from the side opposite the cover sheet, crosses over the laminate, and exits from the cover sheet side.
  • a change in the blowing operation designated herein by the phrase "second blowing phase" comprises a reversal of the direction of blowing phase.
  • a single change i.e., a single reversal of the direction of blown air, is sufficient during the entire pressing operation.
  • the overall duration of the molding operation is generally less than two minutes and thirty seconds.
  • the duration of each of the air blowing phases may vary where more than one air blowing phase is practical, with the first phase possibly being combined with the shaping phase so long as it remains of sufficient duration to set the shape of the panel. For example, with a total pressing time of 90 seconds and using cross-over blowing, one might first blow toward the cover sheet for 60 seconds and then away from it for 30 seconds.
  • the temperature of the blown air may vary considerably depending on the heat required for rapid polymerization of the binder and on the temperatures tolerated by the cover sheet. Generally, temperatures of between 150° C. and 300° C. are used.
  • the flow of blown air may be on the order of 1,000 to 10,000 m 3 /hour (measured under normal conditions) according to the size and density of the panel.
  • the speed of the blown air may be on the order of 0.1 to 10 meters per second.
  • the two half-panels are constructed from a single piece of raw material and a single sheet of covering. To facilitate the later joining of the two half-panels, they are kept connected during molding, with the line of connection acting as a sort of hinge.
  • variable-thickness composite panel such as an acoustical panel that is symmetrical with respect to its principal plane, is between 60 and 150 mm thick, is formed by joining two half-panels that may have a more or less marked hollow interior shape, and is made from a piece of fibrous raw material containing a binder and covered with a facing sheet that is air-permeable.
  • the raw material used in practicing the invention may be based on glass, rock, or slag fibers or on any other type of fiber that will withstand the molding temperatures.
  • the binder contains a resin that is generally thermosetting, such as a phenoplastic or aminoplastic resin.
  • a phenoplastic resin is used that stands up well under the the relatively high temperatures necessary during molding (which may be on the order of 150° C. to 300° C., preferably 150° C.-180° C.), resists humidity, and is low in cost.
  • the binder content of the raw material is generally on the order of 8% to 30% by weight.
  • phenoplastic resins may be phenolformaldehyde resins of the resol type, possibly modified with urea and having a molecular ratio of formaldehyde to phenol of between 1 and 5, catalyzed in an alkaline medium with alkaline or alkaline-earth hydroxides, and neutralized to pH 7 at the end of the cycle by addition of diluted sulfuric acid.
  • a resin is used with a pH of approximately 1.5 to 3 or 8.5 to 12, prepared from the basic pH 7 resin, since these reins demonstrate even better polymerization characteristics (particularly relatively low reticulation temperatures, on the order of 150° C. to 180° C. for relatively brief reticulation periods of one and a half to two minutes for the thickness and weights of the fiber layers used in the invention.)
  • the cover sheet may be made of woven or unwoven natural or synthetic fibers. It must be porous or permeable to air, both to allow air to pass through during the blowing operation and to allow the [inner] fibers to play their sound-absorbent role.
  • the cover must be malleable so as to be able to conform to the shape of the mold. It must be able to withstand the previously indicated molding temperatures. In addition, its texture must allow for the cutting and sealing of the edges.
  • the laminate to be molded may also include a cover sheet for the surface of the panel that is later to be hidden. This sheet facilitates handling of the panel, spares handlers direct contact with the fibers, and may also improve the rigidity of the molded panel.
  • the laminate to be molded may also include other constitutive elements such as a thermoplastic film which, placed between the face cover sheet and the piece of fibrous raw material, is used as an adhesive to improve the bond between the two elements.
  • a thermoplastic film which, placed between the face cover sheet and the piece of fibrous raw material, is used as an adhesive to improve the bond between the two elements.
  • a thermoplastic grid e.g., of polyethylene, may be substituted for the thermoplastic film in order to allow for full cross-over blowing.
  • the invention further concerns means for practicing the process.
  • the means of the invention also comprises a hot-air blowing system linked to the aforesaid ports, blades for cutting the panel during molding, conduction heat elements for the contact parts of the mold and mold-backing i.e., the parts corresponding to the dense parts of the panel, particularly in the vicinity of the edges, with said heating elements possibly disposed either within the material of the mold or mold-backing or in the plates of the press.
  • the mold and mold-backing are both provided with ports in those of their sections that correspond to the thick parts of the panels or half-panels to be produced.
  • FIG. 2 illustrates the panel of FIG. 1 in a side view.
  • a rectangular acoustical panel is to be produced as shown in FIGS. 1 and 2. It is 1,200 mm long, 750 mm wide, 120 mm thick in the thick, absorbent section, and 5 mm thick in the dense area, and has four holes for grommets at the four corners of the dense area, with said grommets being used to fasten the panel in place for use.
  • the piece of raw material or original is covered with an unwoven cotton covering and rests on an unwoven polyester backing that facilitates handling.
  • the raw material is approximately 150 mm thick.
  • the assembly is placed between the mold and mold-backing of the press.
  • the molding is done with stops set so as to obtain the desired thicknesses. Duration of molding is 90 seconds.
  • the portions of the two half-panels having high fiber-density are heated through contact with the corresponding parts of the mold and mold-backing, which are themselves heated to 200° C. by high-temperature oil circulating through them.
  • the thick, sound absorbent sections are heated by blowing hot air at approximately 200° C. and at a pressure of 3,000 m 3 /h (measured under normal conditions), first from below, i.e., from the backing toward the cover sheet that will be seen, for 60 seconds, which has the effect of rapidly polymerizing the binder and giving the panel the desired outer shape, an operation that is further accentuated by the mechanical action of tube belts 31 and 32.
  • the resulting panel has a good appearance, its shape is well defined, the cover fabric is intact, and the edges and grommet holes are perfectly sealed.
  • the two following examples are comparative examples in which not all of the shaping and blowing phases of the invention are used.
  • An acoustical panel is produced in the same manner as in Example 1 except that the direction of blowing is not reversed.
  • An acoustical panel is produced in the same manner as in Example 1 except that air is blown first in the opposite direction, i.e., from the cover sheet toward the backing, and is then reversed.
  • the shape of the resulting panel is imperfectly defined between thick and thin portions.
  • An acoustical panel suitable for use as a hood-liner for a motor vehicle is to be produced. It is approximately 1,400 mm long, 900 mm wide, 40 mm thick through its thick section, and approximately 4 mm in its thin sections.
  • a piece of fiberglass raw material having a surface density of 1,100 g/m 2 and phenoplastic resin-based binder content of 17% by weight as described in Example 1.
  • the raw material is covered with a pricked fabric on the side that is to be visible, while the side that will remain unseen rests on an unwoven backing.
  • An interior roof fitting for a motor vehicle is to be produced using the means illustrated in FIGS. 5 and 6.
  • a piece of fiberglass raw material is used having a surface density of 800 g/m 2 and a phenoplastic reinbased binder content of 15% by weight as described in Example 1, except that it has a pH of 9.2.
  • the raw material is covered with a polyester fabric cover sheet over a sheet of polyvinyl chloride and rests on an unwoven fabric used as a hidden backing.
  • the stratified assembly is placed in the mold, with the cover sheet arranged to face mold 34.
  • three-way valve 57 is used to close the recycling circuit and air is introduced into the supply circuit by switching on fan 54.
  • flap-valve 59 With the exhaust circuit closed by flap-valve 59, the mold is pressurized.
  • valve 59 is opened and, after fan 58 is activated, air heated by reheater 55 may the circulate within the composite panel, being introduced through ports 40 in every other groove of the mold-backing and, after moving into the composite panel, escaping through the remaining grooves and ports 44 toward the exhaust circuit.
  • the blowing operation is changed by simultaneously activating actuators 49 and 50 that act upon slide-valves 47 and 48 so as to place the holes in the slide-valves opposite the previously unused ports 40 and 44.
  • the flow of air within the composite panel is thereby reversed.
  • the three-way valve is placed in recycling position, flap-valve 59 is closed, the mold is opened, and the molded composite panel is removed. It is of good appearance and has good mechanical properties.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Moulding By Coating Moulds (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Road Signs Or Road Markings (AREA)
  • Meat, Egg Or Seafood Products (AREA)
  • Seeds, Soups, And Other Foods (AREA)
  • Baking, Grill, Roasting (AREA)
  • Steam Or Hot-Water Central Heating Systems (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Paper (AREA)
  • Magnetic Resonance Imaging Apparatus (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)
US06/590,481 1983-03-17 1984-03-16 Processes for making molded composite panels Expired - Fee Related US4609519A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR8304358 1983-03-17
FR8304358A FR2542666B1 (fr) 1983-03-17 1983-03-17 Panneaux composites moules

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US4609519A true US4609519A (en) 1986-09-02

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EP (1) EP0124387B1 (OSRAM)
JP (1) JPS59194815A (OSRAM)
KR (1) KR910005172B1 (OSRAM)
AT (1) ATE35939T1 (OSRAM)
AU (1) AU2518484A (OSRAM)
BR (1) BR8401216A (OSRAM)
CA (1) CA1229295A (OSRAM)
DE (1) DE3472922D1 (OSRAM)
DK (1) DK75684A (OSRAM)
ES (1) ES530718A0 (OSRAM)
FI (1) FI841070A7 (OSRAM)
FR (1) FR2542666B1 (OSRAM)
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US5407610A (en) * 1990-02-06 1995-04-18 Honda Giken Kogyo Kabushiki Kaisha Method for molding fiber-reinforced resin
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US5679296A (en) * 1995-09-29 1997-10-21 Davidson Textron, Inc. Cushioned automotive interior trim part and process or making same
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US6202998B1 (en) 1999-12-03 2001-03-20 Lear Corporation Apparatus for supporting a sheet material along its peripheral edges
US20010024727A1 (en) * 1996-12-11 2001-09-27 Boise Cascade Corporation Apparatus and method for continuous formation of composites having filler and thermoactive materials, and products made by the method
US6344249B1 (en) * 1999-03-11 2002-02-05 Mitsubishi Gas Chemical Company, Inc. Multi-layered article
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
US6506325B1 (en) * 1999-02-05 2003-01-14 The B. F. Goodrich Company Method controlling the exotherm of a vacuum resin infusion
US6537483B1 (en) * 1999-02-05 2003-03-25 The B. F. Goodrich Company Pressure equalized vacuum resin infusion process
EP1304201A1 (en) * 2001-10-17 2003-04-23 Persico S.p.A. Plant for preheating porous thermoformable material and pressing method
US20050082111A1 (en) * 2003-10-18 2005-04-21 Sika Technology Ag Acoustic baffle
WO2007022970A1 (de) * 2005-08-23 2007-03-01 Airbus Deutschland Gmbh Pressvorrichtung zur energieeffizienten aushärtung eines sandwichbauteils für luftfahrzeuge
CN100580166C (zh) * 2007-11-28 2010-01-13 盛虹集团有限公司 内部热粘结无纺布的制造
US20100055420A1 (en) * 2007-04-10 2010-03-04 Spanolux N.V. -Div.Balterio Method and apparatus for manufacturing laminate floor panels comprising a core containing wood/plastic composite, as well as such panels
US20110031660A1 (en) * 2009-08-05 2011-02-10 Huff Norman T Method of forming a muffler preform
US20110031654A1 (en) * 2009-08-05 2011-02-10 Huff Norman T Process for curing a porous muffler preform
US20110047768A1 (en) * 2009-08-28 2011-03-03 Huff Norman T Apparatus And Method For Making Low Tangle Texturized Roving
DE102009050860A1 (de) * 2009-10-27 2011-04-28 Dbw Holding Gmbh Formgebungsverfahren und Vorrichtungen hierfür
US20150091209A1 (en) * 2012-04-18 2015-04-02 Knauf Insulation Gmbh Molding apparatus and process
US20150367583A1 (en) * 2012-12-20 2015-12-24 Airbus Operations (S.A.S.) Process for manufacturing a textile preform with continuous fibres by circulation of hot gas flow through a fibrous array
US9457499B2 (en) 2013-03-15 2016-10-04 Herman Miller, Inc. Particle foam component having a textured surface and method and mold for the manufacture thereof
CN107415220A (zh) * 2017-06-16 2017-12-01 桂林市新众科技有限公司 3d打印喷头装置
US10105938B2 (en) 2012-05-29 2018-10-23 Airbus Operations (S.A.S.) Self-stiffened composite panel and method of producing same
US10300762B2 (en) * 2016-04-20 2019-05-28 Toledo Molding & Die, Inc. Method of making an acoustic automotive HVAC and AIS duct with a particle fiber slurry
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US4802948A (en) * 1985-01-17 1989-02-07 Ford Motor Company Apparatus for producing interior trim component for a motor vehicle
US4812283A (en) * 1986-05-02 1989-03-14 Allied-Signal Inc. Method of manufacture of formed article
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US4979890A (en) * 1986-10-06 1990-12-25 Sicam Societa' Italiana Cuscini A. Molle S.P.A Apparatus for the manufacture of a padded element, particularly a seat cushion
US4988469A (en) * 1988-11-21 1991-01-29 United Technologies Corporation Method of fabricating fiber reinforced composite articles by resin transfer molding
US5501832A (en) * 1989-07-27 1996-03-26 Group Lotus Limited Method and apparatus for forming a moulded article incorporating a reinforcing structure
US5407610A (en) * 1990-02-06 1995-04-18 Honda Giken Kogyo Kabushiki Kaisha Method for molding fiber-reinforced resin
US5080851A (en) * 1990-09-06 1992-01-14 United Technologies Corporation Method for stabilizing complex composite preforms
US5824246A (en) 1991-03-29 1998-10-20 Engineered Composites Method of forming a thermoactive binder composite
US5639411A (en) * 1994-12-21 1997-06-17 Holli-Nee Corporation Process for expanding glass fiber laminates and panels formed thereby
US5908596A (en) * 1994-12-21 1999-06-01 Nicofibers, Inc. Process and apparatus for expanding and molding fiberglass laminate and the panel formed thereby
US5679296A (en) * 1995-09-29 1997-10-21 Davidson Textron, Inc. Cushioned automotive interior trim part and process or making same
WO1998024615A1 (en) * 1996-12-02 1998-06-11 Owens Corning Molded insulation products and their manufacture using continuous-filament wool
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US5766541A (en) * 1996-12-03 1998-06-16 O-C Fiberglas Sweden Ab Method and apparatus for making preforms from glass fiber strand material
US6863512B2 (en) 1996-12-11 2005-03-08 Officemax Incorporated Apparatus and method for continuous formation of composites having filler and thermoactive materials, and products made by the method
US20010024727A1 (en) * 1996-12-11 2001-09-27 Boise Cascade Corporation Apparatus and method for continuous formation of composites having filler and thermoactive materials, and products made by the method
US6036896A (en) * 1998-05-21 2000-03-14 Lear Corporation Method for preheating permeable, thermoformable material
US5976453A (en) * 1998-06-29 1999-11-02 Owens-Corning Sweden Ab Device and process for expanding strand material
US6153144A (en) * 1998-10-08 2000-11-28 Lear-Donnelly Overhead Systems, L.L.C. Method of making a part using selective particulate deposition
US6101304A (en) * 1998-10-28 2000-08-08 Sumitomo Electric Lightwave Corp. Air blown fiber (ABF) tube cable with central innerduct
US6506325B1 (en) * 1999-02-05 2003-01-14 The B. F. Goodrich Company Method controlling the exotherm of a vacuum resin infusion
US6537483B1 (en) * 1999-02-05 2003-03-25 The B. F. Goodrich Company Pressure equalized vacuum resin infusion process
US6344249B1 (en) * 1999-03-11 2002-02-05 Mitsubishi Gas Chemical Company, Inc. Multi-layered article
US6736915B2 (en) 1999-12-03 2004-05-18 Lear Corporation Method of forming a headliner
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
US6202998B1 (en) 1999-12-03 2001-03-20 Lear Corporation Apparatus for supporting a sheet material along its peripheral edges
US20020112806A1 (en) * 1999-12-03 2002-08-22 Lear Corporation Method of forming a headliner
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US20050082111A1 (en) * 2003-10-18 2005-04-21 Sika Technology Ag Acoustic baffle
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US20090155403A1 (en) * 2005-08-23 2009-06-18 Airbus Deutschland Gmbh Press Device for the Energy-Efficient Curing of a Sandwich Component for Aircraft
US8740606B2 (en) * 2005-08-23 2014-06-03 Airbus Operations Gmbh Press device for the energy-efficient curing of a sandwich component for aircraft
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US8956714B2 (en) 2007-04-10 2015-02-17 Spanolux N.V.-Div. Balterio Method and apparatus for manufacturing laminate floor panels comprising a core containing wood/plastic composite, as well as such panels
CN100580166C (zh) * 2007-11-28 2010-01-13 盛虹集团有限公司 内部热粘结无纺布的制造
US9211661B2 (en) 2009-08-05 2015-12-15 Ocv Intellectual Capital, Llc Process for curing a porous muffler preform
US8623263B2 (en) 2009-08-05 2014-01-07 Ocv Intellectual Capital, Llc Process for curing a porous muffler preform
US20110031654A1 (en) * 2009-08-05 2011-02-10 Huff Norman T Process for curing a porous muffler preform
US20110031660A1 (en) * 2009-08-05 2011-02-10 Huff Norman T Method of forming a muffler preform
US8474115B2 (en) 2009-08-28 2013-07-02 Ocv Intellectual Capital, Llc Apparatus and method for making low tangle texturized roving
US20110047768A1 (en) * 2009-08-28 2011-03-03 Huff Norman T Apparatus And Method For Making Low Tangle Texturized Roving
DE102009050860A1 (de) * 2009-10-27 2011-04-28 Dbw Holding Gmbh Formgebungsverfahren und Vorrichtungen hierfür
DE102009050860B4 (de) * 2009-10-27 2017-03-23 Dbw Holding Gmbh Formgebungsverfahren
US20150091209A1 (en) * 2012-04-18 2015-04-02 Knauf Insulation Gmbh Molding apparatus and process
US11318639B2 (en) 2012-04-18 2022-05-03 Knauf Insulation, Inc. Molding apparatus and process
US10889026B2 (en) 2012-04-18 2021-01-12 Knauf Insulation, Inc. Molding apparatus and process
US10105938B2 (en) 2012-05-29 2018-10-23 Airbus Operations (S.A.S.) Self-stiffened composite panel and method of producing same
US9597844B2 (en) * 2012-12-20 2017-03-21 Airbus Operations (S.A.S.) Process for manufacturing a textile preform with continuous fibres by circulation of hot gas flow through a fibrous array
US20150367583A1 (en) * 2012-12-20 2015-12-24 Airbus Operations (S.A.S.) Process for manufacturing a textile preform with continuous fibres by circulation of hot gas flow through a fibrous array
US9457499B2 (en) 2013-03-15 2016-10-04 Herman Miller, Inc. Particle foam component having a textured surface and method and mold for the manufacture thereof
US10300762B2 (en) * 2016-04-20 2019-05-28 Toledo Molding & Die, Inc. Method of making an acoustic automotive HVAC and AIS duct with a particle fiber slurry
CN107415220A (zh) * 2017-06-16 2017-12-01 桂林市新众科技有限公司 3d打印喷头装置
EP3705281A1 (en) * 2019-03-04 2020-09-09 The Boeing Company Tooling assembly and associated system and method for manufacturing a porous composite structure
CN111645337A (zh) * 2019-03-04 2020-09-11 波音公司 用于制造多孔复合结构的工具组件以及相关的系统和方法
US11413833B2 (en) 2019-03-04 2022-08-16 The Boeing Company Tooling assembly and associated system and method for manufacturing a porous composite structure
US11534992B2 (en) 2019-03-04 2022-12-27 The Boeing Company Tooling assembly and associated system and method for manufacturing a porous composite structure
CN111645337B (zh) * 2019-03-04 2023-09-19 波音公司 用于制造多孔复合结构的工具组件以及相关的系统和方法
AU2020200879B2 (en) * 2019-03-04 2025-05-22 The Boeing Company Tooling assembly and associated system and method for manufacturing a porous composite structure

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ES8500366A1 (es) 1984-11-01
TR22582A (tr) 1987-12-02
KR910005172B1 (ko) 1991-07-23
PT78269B (fr) 1986-05-21
CA1229295A (fr) 1987-11-17
FI841070A7 (fi) 1984-09-18
NO165139B (no) 1990-09-24
ZA841628B (en) 1985-06-26
FI841070A0 (fi) 1984-03-16
ES530718A0 (es) 1984-11-01
EP0124387B1 (fr) 1988-07-27
PT78269A (fr) 1984-04-01
DE3472922D1 (en) 1988-09-01
AU2518484A (en) 1986-03-20
EP0124387A1 (fr) 1984-11-07
FR2542666B1 (fr) 1986-06-20
DK75684A (da) 1984-09-18
KR850000018A (ko) 1985-02-25
NO841035L (no) 1984-09-18
ATE35939T1 (de) 1988-08-15
GR81776B (OSRAM) 1984-12-12
JPS59194815A (ja) 1984-11-05
BR8401216A (pt) 1984-10-23
FR2542666A1 (fr) 1984-09-21
DK75684D0 (da) 1984-02-17
NO165139C (no) 1991-01-09
JPH0522578B2 (OSRAM) 1993-03-30

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